PROJECT

H2INTEGRA Project

OBJECTIVES

The H2INTEGRA project is born out of this environment, committed to investigating physical and digital solutions that will enable us to prime an ecosystem for the optimal connectivity and management of hydrogen generation, distribution and final use.

TECHNICAL SCOPE OF THE PROJECT

H2INTEGRA is conducting research with the aim of developing a unique infrastructure, consisting of:

1

ELECTROLYSER
A 2.5 MW electrolyser located at Muskiz Industrial Complex

2

HYDROGEN PIPELINE
A pipeline, already built by NORTEGAS, to transport hydrogen at a maximum pressure of 30 bars from Muskiz to Abanto Technology Park, to supply a data centre (3), a compression and storage station (4) and a hydrogen refuelling station (HRS) (5).

3

DATA CENTER
Hydrogen is piped into the Data Center as back-up power. The data center is located in Abanto Technology Park, a short distance from the storage and compression facility.

4

STORAGE AND COMPRESSION STATION
Hydrogen is piped at 30, 300, 500 and 900 bars into IBIL compression and storage station, where there are loading bays for the MECG (Multiple Element Gas Container) trucks used to supply hydrogen to the airport (6), port of Bilbao (7) and industrial plants (8).

5

HYDROGEN REFUELLING STATION (HRS)
Hydrogen is piped to a hydrogen refuelling station for light and heavy vehicles.

6

MOBILE HYDROGEN REFUELING STATION
MEGC trucks transport hydrogen to a mobile hydrogen refuelling station at Bilbao airport, where it is used to refuel handling vehicles airside and light and heavy vehicles on the ground.

7

FREIGHT CRANES
MEGC trucks supply hydrogen to freight cranes on the docks.

8

TUBES AND PACKAGING
Prototypes may be installed for early testing of hydrogen generation for steel tubes and aluminium packaging, both made in Álava, pending supply at a later date via MEGC trucks or pipelines.

9

HYDROGEN PURIFICATION AND SEPARATION
Injected, blended hydrogen carried in the natural gas system needs to be separated.

10

SECURITY ELEMENTS
Because security is crucial to all hydrogen-related activities, the infrastructure is fitted with the necessary security elements.

11

DIGITAL PLATFORM
The infrastructure is communicated via a digital platform (IoT), which captures data on hydrogen demand in order to its generation, compression, storage, logistics and distribution.

RESEARCH AREAS

To leverage this infrastructure, the H2INTEGRA consortium will work in the following research areas:

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Management and optimisation of production and distribution.
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Oxygen from electrolyser used in furnaces.

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Monitoring and predicting storage, compression, distribution and use processes.
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Data centre decarbonisation solutions.
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Use in heat-intensive industries.

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New hydrogen-based propulsion systems for freight cranes.
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Upgrading of infrastructures.

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Separation of hydrogen transported in natural gas.

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Compact, portable system for on-site hydrogen generation.
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New tools, strategies and systems for infrastructure security and integrity.

EXPECTED RESULTS

Production of competitive renewable hydrogen (350 tn/year)

New compact, on-site green hydrogen generation system and two re-heating furnaces in place for heat treatment on green steel and packaging production lines.

Hydrogen fuel cells to supply a data center to cover the required quality level and technical and functional requirements

Risk assessment tools in place to optimise safe/investment ratio in the desing of hydrogen based industrial systems

Hydrogen compression, storage and distribution facility and MEGC fleet optimised.

Unit in place for separating hydrogen from natural gas, optimising reactor design and components

Hydrogen cell systems in place for port freight cranes.

Production and demand coupling platform in place, to optimise hydrogen distribution

THE CONSORTIUM

PETRONOR is responsible for specifying operational strategies for the value chain to act with high energy efficiency ratios while allowing it to operate at high efficiency standards with respect to the supply times required. It will also develop algorithms with AI applications and numerical interactions for 24 h demand forecasting. In addition, it will implement operating applications with real-time logic that adjusts, on an hourly basis, the variations that occur.

ALBA will take part in hydrogen production monitoring research and production optimisation service analysis, following an established plan.

CSP will carry out the research, development and detailed engineering for the refurbishment of a Rubber Tyred Gantry Crane (RTG), which handles containers in the container yard of CSP’s terminal in the Port of Bilbao. The study will determine whether the RTG currently powered by a Diesel-Generator set can be converted to be propelled by a Hydrogen Fuel Cell, preserving all the safety guarantees, the same working performance and autonomy.

FERRO will conduct research into hydrogen-based propulsion systems for port gantries, as well as developing basic and detailed mechanical engineering plans, support element and structure layout for structural implantation and calculation, basic and detailed electrical plans, PLC programming and electrical diagrams and calculations.

ENVASES will carry out an industrial feasibility analysis of the use of H2 as an alternative to the current Natural Gas (NG) in its aluminium packaging production lines. It will study in detail the current demand for NG in the different consumption points, to understand and optimise these demand profiles to the case of H2 (limited resource) and will analyse the viability of the current facilities for use with H2.

H2SITE will advance in more efficient production-scale processes, scaling hydrogen production capacity up by one order of magnitude (x100 tonnes per day over previous versions), as well as working on optimising and standardising the design of the hydrogen separators, to reduce working time by 50% Both of these targets may be adapted to the size needs of new hydrogen uses, while also improving customer service.

IBIL will design an IoT platform to monitor hydrogen consumption and will also optimise the logistics associated with hydrogen distribution and supply, with the aim of implementing these developments in the Abanto-Zierbena Hydrogen Logistics Centre.

NORTEGAS will design, develop and test advanced membranes with a view to obtaining a CH4 current with 2% H2 at most at a competitive rate, starting from a blended supply of H2-CH4 with a H2 content of 5-20%.

PQC will apply R+D to conceptualise an ad hoc process for the design and coordination of high-availability data centres, maintaining the same level of quality and technical and functional requirements, supplied by green hydrogen.

SARRALLE will undertake the conceptual design to supply hydrogen by means of a compact, portable electrolyser, based on the type, number and power of the electrolysis stacks, and the plant balance required for them. They will also conduct a study to integrate H2 use into heating equipment at the Tubos Reunidos and Envases Álava plants.

TEAM INGENIERÍA will develop tools for harmonised risk assessment and management, making it possible to optimise the safety/investment ratio in H2-based industrial system design. To this end, an initial overall multi-risk approach will be used, defining the H2SAFEY concept (with an optimal security/investment ratio), followed by the development of specific algorithms for the applications covered by the project.

TUBOS REUNIDOS GROUP manufactures seamless tubes in stainless steel, high-performance alloys and carbon alloy steel. Tubos Reunidos will conduct research into upgrading the facilities in order to implement hydrogen in metal heating equipment, as well as conceptualizing a new hydrogen generation system.

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